I made a 10 Ah solar powered charger! It uses an Adafruit solar/DC battery charger board and a 5V booster. The case is 3D-printed in two parts – the lower shell and the lid. As is visible, the lid screws down into the shell. Both boards that things plug into are screwed down as well for better stability. My Apple devices wouldn’t charge from it at first, and I learned that they need specific voltages on the data lines (or, presumably, USB PD, but that’s way harder) to determine how many mA is safe to draw.
I’ve been keeping it by my south-facing window plugged into a 20W solar panel and using it to charge my devices, but there are cheaper still-6V options if lower wattages work for your use case.
If you’re interested – more details:
I needed to add a thermistor to the battery to safely charge at higher than 1A, which seemed especially important given that I wanted to output 1A and the solar board will not draw more than the maximum charge rate from its sources. Then I was able to cut the 1.0A selector and solder the 1.5A, as is visible on the board.
The resistors you can barely see in the middle upper part of the board was for an ill-fated LED to show whether it was charging. It was too bright, broke off, and was redundant when you can look in through the gap around the USB in and see the LEDs on the solar board anyway if you really want to. The existing red charging LED even makes the lid glow in dim enough light. I had made holes for what was going to be external counterparts to the red and green status LEDs and that was very, very unnecessary.
Early on aligning the holes correctly was difficult, so for more than one case I ended up ripping the wall apart until things were situated correctly. The data line voltages I made with voltage dividers and this handy Adafruit diagram:
Lacking those exact resistor values, I found values with the same ratios that were close enough: 100k on the D+ line, 47k + 10k on the D-, and after two 47k + 22k.
Parts, as sold by Adafruit:
- 10 Ah battery – $30
- 10K precision epoxy NTC thermistor – $4
- USB / DC / Solar charger – $15
- MiniBoost 5V @ 1A – $4
- Half-sized Perma-Proto – $4.50
- USB C breakout – $3
- Solar panel DC jack adapter – $1.50
- 6V solar panel – 20W for example – $99
Together with:
- an estimated $1.85 of PLA
- JST XH header and plug for the thermistor (and tape to tape it to the battery)
- three M2.5×5 (the solar board can accommodate up to 10mm length; I don’t remember why I did that)
- M3x35, and an M3x10 if you want the breadboard to be very secure, though in my experience screwing down the boards is more than enough
- the resistors
The breakdown totals to $162.85, so let’s say you can build this solar powered charger box thing for maybe $170 or so! (Depending on how much of the incidentals you already have of course.) It’s the opposite of a deal, but it’s fun! The battery is held in place with sheer tightness of fit and yet does not rattle, which I’m proud of. It does mean that you need some kind of hook to coax it up and out, which I’ve been using curved tweezers for (with the soft plastic tip cover left on), and that is preferable to adhesive in my book. The files for the case:
- Fusion 360 project
- 3mfs for Prusa Slicer 2.9 or higher because they use its fuzzy skin painting: lower shell, lid